Simulations and Experiments on the Micro-Milling Process of a Thin-Walled Structure of Al6061-T6

Sun, Qi; Zhou, Jing; Li, Pengfei

doi:10.3390/ma15103568

Cited by 8 publications

(2 citation statements)

References 32 publications

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“…The environment variable parameters are specified as a single variable in order to have a good comparison and point of reference between the simulation and the physical experiment. It is assumed that the machine tool, fixture, and tool are all rigid bodies and that the ambient temperature is always 20℃ 24 .…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell

Zhao,

Cao,

Bai

et al. 2024

Sci Rep

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Due to its challenging manufacturing and intricate morphology, the aluminum alloy transmission intermediate shell used in vehicle transmission has been the focus of many academic studies. In this study, the three-dimensional cutting model is condensed to a two-dimensional cutting model and utilized to simulate the finishing process of an aluminum alloy workpiece using the finite element modeling program DEFORM-3D. Through orthogonal testing and range analysis, the impact of integral end mill side edge parameters on cutting performance was investigated. It is determined that tool chamfering has a greater impact on cutting performance than tool rake and relief angles, that chamfering width has the most impact on cutting force, and that chamfering angle has the greatest impact on cutting temperature. The workpiece's surface roughness is tested during a cutting experiment, and an analysis of the data reveals that the finite element simulation model is accurate and the orthogonal test method is reasonable. The tool chamfer has a greater impact on roughness than the tool rake angle and relief angle. The tool settings are further optimized using the firefly method. By examining the data, it is determined that the prediction model is correct and the optimization model is reasonable. The cutting efficiency is higher and the surface quality is better when the chamfer width is 0.17 mm and the chamfer angle is 7.3° or 18.3°. Therefore, optimizing the side edge parameters of the integral end mill during the finishing process of a thin-walled aluminum alloy shell has practical technical value.

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Section: Introductionmentioning

confidence: 99%

Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell

Zhao,

Cao,

Bai

et al. 2024

Sci Rep

View full text Add to dashboard Cite

show abstract

“…Aluminum alloy has the characteristics of good corrosion resistance and high strength, so aluminum alloy workpiece is widely used in the aerospace field. However, aluminum alloy is prone to deformation during milling, which seriously threatens aviation safety [1][2][3][4]. As one of the important indicators to measure the integrity of the machined surface, residual stress is the main reason for the machining deformation and dimensional instability of aluminum alloy workpiece.…”

Section: Introductionmentioning

confidence: 99%

Residual stress formation mechanism considering cutting energy in milling of 7075 aluminum alloy

Zheng,

Tian,

et al. 2023

Int J Adv Manuf Technol

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Aluminum alloy has the characteristics of good corrosion resistance and high strength, so aluminum alloy workpiece is widely used in the aerospace field.However, in milling, the surface of the aluminum alloy workpiece generates residual stress due to the coupling of force and heat, which seriously affects the fatigue performance of the workpiece. To investigate the residual stress formation mechanism, an analyzed model of machining-induced residual stress considering energy conversion in milling process was proposed. In this process, the milling force prediction model is established. Then, an effective cutting work model is established based on the milling force model. After that, the strain energy density of the machined surface layer was analyzed and the strain energy solution model was established.Subsequently, the prediction models of mechanical stress, thermal stress and residual stress are established respectively, and the residual stress data are brought into the strain energy model to obtain the strain energy. Afterwards, the functional transformation relationship between effective cutting work and strain energy storage per unit time is analyzed. Finally, several milling experiments were carried out to verify the predicted milling force and residual stress. Experimental results show that errors between the predicted results and the experimental results are about 5 % and 15 %, respectively, and the functional transformation results show that the stored strain energy per unit time increases with the increase of the effective cutting work.

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Mechanism of dual-direction vibration-assisted (DVA) micro-milling in surface formation considering the tool life-lengthening effect on the Ti6Al4V: design and experiment

Guo

Liao

et al. 2022

Int J Adv Manuf Technol

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Simulations and Experiments on the Micro-Milling Process of a Thin-Walled Structure of Al6061-T6

Cited by 8 publications

References 32 publications

Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell

Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell

Residual stress formation mechanism considering cutting energy in milling of 7075 aluminum alloy

Mechanism of dual-direction vibration-assisted (DVA) micro-milling in surface formation considering the tool life-lengthening effect on the Ti6Al4V: design and experiment

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